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You gotta estimate it for yourself, there's no set size here. Look at how much substrate you have on hand, what size containers are available to you, and how deep of a substrate you're aiming for. Once you have all that information, make an educated guess.

It's too general of a question, no one can pipe in and say "Hey, use that one baking tin with AxBxC dimensions, that's exactly what you need".

If you can get ahold of some horse manure, you should look into bulk spawning that puppy. It really isn't difficult if ya read up on it a bit. If you're set on just casing the jar on it's own, I'd say your best bet is some type of plastic tupperware container. I like the deep gladware containers, myself (the ones that are about 6 inches deep or so). Remember you don't want the substrate to be too shallow, and you also want to leave an inch or two of space for your casing material. Good luck!

What makes you think the problem is the spores? Sounds like you might have a contam or something, or maybe you used a bit too much lysol. Hard to say, but it doesn't sound like defective spores to me, especially if you've had the same problem with two different strains.